THE CHEMICAL SAFETY AUDIT PROGRAM: FY 1995 STATUS REPORT June 1996 TABLE OF CONTENTS EXECUTIVE SUMMARY .............................................................i 1.0 CHEMICAL SAFETY AUDIT PROGRAM: HISTORY AND FUTURE ................. 1 1.1 Future Role of the CSA Program ........................................... 1 1.2 CSA Training Workshop ................................................. 2 1.3 CSA Program Modifications .............................................. 3 1.4 CSA Database ......................................................... 5 1.5 CSA Program Background ............................................... 6 2.0 OVERVIEW OF CSA PROGRAM RESULTS ..................................... 11 2.1 Chemical Safety Audits and Reports Completed ............................. 11 2.2 Chemical Safety Audits by SIC Code ...................................... 11 2.3 Chemical Safety Audits by Hazardous Substance ............................. 15 2.4 CSA Training Workshops ............................................... 15 3.0 STATUS OF CSA PROGRAM IMPLEMENTATION ............................... 21 3.1 Regional CSA Status ................................................... 21 3.2 Regional CSA Implementation Activities ................................... 21 3.2.1 Follow-up Activities .............................................. 21 3.2.2 Regional CSA Program Initiatives ................................... 22 3.2.3 State and Local Coordination ....................................... 24 4.0 OVERVIEW OF CSA REPORT RESULTS ....................................... 27 4.1 Corporate and Facility Management ....................................... 28 4.2 Process Hazard Analysis (Hazard Evaluation) ............................... 29 4.3 Offsite Consequence Analysis ............................................ 30 4.4 Process Safety Information .............................................. 31 4.5 Standard Operating Procedures ........................................... 33 4.6 Equipment and Instrument Maintenance .................................... 34 4.7 Training ............................................................. 36 4.8 Safety Audits ......................................................... 37 4.9 Accident Investigation .................................................. 38 4.10 Management of Change ................................................. 39 4.11 Pre-Startup Review .................................................... 40 4.12 Hot Work Permits ..................................................... 41 4.13 Employee Participation ................................................. 41 4.14 Contractors ........................................................... 42 4.15 Release Prevention and Mitigation Measures ................................ 43 4.16 Facility Emergency Preparedness and Response .............................. 44 4.17 Community Emergency Response Coordination ............................. 49 APPENDICES Appendix A: Outline of the Chemical Safety Audit Protocol Appendix B: List of Chemical Safety Audits EXHIBITS Exhibit 1: Summary of Chemical Safety Audits and Final Reports by Year and Region Exhibit 2: Summary of Chemical Safety Audits and Final Reports Completed by Region Exhibit 3: Breakdown of Audited Facilities by SIC Code Exhibit 4: Hazardous Substances Examined, FY 89 through FY 95 Exhibit 5: Chemical Safety Audit Workshop Attendees by Affiliation, FY 89 through FY 95 Exhibit 6: Chemical Safety Audit Workshop Attendees by Affiliation Exhibit 7: Chemical Safety Audit Workshops: Number of Persons Trained by EPA Region EXECUTIVE SUMMARY This report is a comprehensive overview of the status of the U.S. Environmental Protection Agency's Chemical Emergency Preparedness and Prevention Office's (CEPPO) Chemical Safety Audit (CSA) program since its inception in fiscal year (FY) 89, a review of the successful and problematic trends of CSA program implementation in FY 95, and a discussion of the future direction of the program. The CSA program evolved from the efforts of CEPPO under the Chemical Accident Prevention (CAP) program into a program which this year alone encompassed the review of the chemical process safety management systems of over 40 facilities and the training of over 200 federal, state, and local officials. In addition, the CSA program continued the development of a database of chemical safety audit information and supported numerous other related CAP activities, including outreach and technical assistance for both the public and private sector. The primary objectives of the CAP program are to identify the causes of accidental releases of hazardous substances and the means to prevent them from occurring, to promote industry initiatives in these areas, and to share the results with the community, industry, and other interested groups. EPA established the CSA program as part of this broad initiative. The purposes of the CSA program are: � To visit facilities handling hazardous substances to gather information on safety practices and technologies; � To heighten awareness of the need for, and promote, chemical safety among facilities handling hazardous substances, as well as in communities where chemicals are located; � To build cooperation among facilities, EPA, and other authorized parties by conducting joint audits; and � To establish a database for the assembly and distribution of chemical process safety management information obtained from the facility audits. The CSA program is not a compliance or regulatory program; however, EPA does have legal authority for entering a facility and conducting a chemical safety audit under sections 104(b) and 104(e) of the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA). The audit consists of interviews with facility personnel and an on-site review of various aspects of facility operations related to the prevention of accidental chemical releases. Observations and conclusions from the audit are detailed in a report, available to the public, that identifies both problematic and successful chemical process safety management practices, as well as technologies for preventing and mitigating chemical releases. This status report is intended to provide EPA headquarters and regional management with a better understanding of how the program is being implemented both at headquarters and in the regions, the purpose and goals of the audit program, and the type of information being generated and its uses. The following four topics are the focus of this report � program activities, program results, regional program implementation, and analysis of audit results. ii Program Activities/Results In June 1993, CEPPO issued a revised edition of the Guidance Manual for EPA Chemical Safety Audit Team Members, which outlines the two important modifications to the CSA program that were implemented in the past several years � the institution of audit follow-up activities and the preparation of audit report profiles by the regional offices. To supplement the audit and audit report preparation, the regional offices were requested to establish an audit follow-up program. In FY 95, the regional offices continued to implement follow-up programs, ranging from conference calls involving the audit team and facility representatives to site visits conducted by audit team members to follow-up questionnaires sent to audited facilities. In addition, many of the regional offices have been preparing an audit report profile in conjunction with the submission of the chemical safety audit report. The profile is a summary document that organizes the key information in the audit report in a format compatible with the CSA program database. The profiles submitted by the regions over the last several years represent an important element in streamlining program analysis; headquarters continues to work with the regions to ensure that the information submitted in the profiles is consistent with the format of the CSA database. The achievements of the audit program, outlined in Chapter 2, are based on the number of audits conducted and reports completed in each region, along with a summary of the audits by the facility's Standard Industrial Classification (SIC) code and by the hazardous substances examined during the audit. An overview of participation in training workshops offered by EPA headquarters is also included. As of the close of FY 95, the regions had submitted a total of 310 final audit reports to EPA headquarters for the 325 audits that were conducted between FY 89 and FY 95, including several follow- up reports on previously audited facilities. Information from the 40 most recently submitted reports was examined for this status report, including a number of reports from audits conducted in FY 94 that were not submitted to EPA headquarters in time to be included in the FY 94 Status Report. CEPPO has designed a four-day chemical safety audit workshop that gives potential audit team members the training to conduct an audit; beginning in FY 93, these courses have been presented by EPA's Environmental Response Team as part of their regular training curriculum. From FY 89 through FY 95, a total of 38 workshops, attended by over 1000 individuals throughout all ten regions, have been conducted; almost 250 individuals attended the ten workshops held in FY 95. The most noteworthy trend in these workshops has been the increased involvement of state and local officials, who account for approximately 45 percent of the overall attendance, but two-thirds of the attendees in the past year.